Conditioning system and method for use in the measurement of mercury in gaseous emissions

ABSTRACT

Embodiments of the invention relate generally to systems used to measure mercury in gaseous emissions. In one aspect, the invention is directed to the use of silicon carbide as material for a thermal pyrolysis unit. In another aspect, at least one of silicon nitride, silicon boride, and/or boron nitride is used as material for a thermal pyrolysis unit. In another aspect, the invention is directed to an improved pyrolyzer design, in which a thermal pyrolysis unit comprises a tailpiece that allows water to be injected at the heated exit of the thermal pyrolysis unit. In another aspect, the invention is directed to the use of a coalescing filter in a scrubbing unit. In another aspect, the invention is directed to the use of a hydrophobic filter element in a scrubbing unit. One or more of these elements may be used in a conditioning module of a continuous emissions monitoring system, for example.

CROSS-REFERENCE TO RELATED APPLICATION

This is a divisional application of U.S. application Ser. No.10/931,987, filed Sep. 2, 2004 now U.S. Pat. No. 7,618,581, U.S.application Ser. No. 10/931,987 is a non-provisional application of U.S.Application No. 60/503,894 filed Sep. 22, 2003. The contents of U.S.Application Nos. 60/503,894 and 10/931,987 are incorporated herein byreference.

FIELD OF THE INVENTION

The present invention relates generally to mercury detection systems,and more particularly to conditioning systems and methods that may beemployed in the measurement of gaseous mercury in combustion and processgas emissions.

BACKGROUND OF THE INVENTION

Governments, power utilities and researchers have recognized the needfor a viable system to continuously detect and monitor mercury emissionsin stack emissions and process gases. A number of proposed solutionsexist in the prior art.

For example, some known conventional direct wet chemical analyzers usewet chemical reagents to condition gas samples for subsequent analysisby atomic absorption (AA) detectors, for example. Stannous chloride,sodium borohydride, or other chemical reductants may be used to convertthe different mercury species to elemental form. However, theseanalyzers may suffer problems with sensitivity since the AA detectorsgenerally have detection limits in the 1 μg/m³ range and cannotquantitate values of less than several μg/m³. While these analyzers maybe useful in monitoring the emissions of waste incinerators for example,they are less useful in monitoring mercury in power plant emissionswhere greater sensitivity is required.

Another known wet chemical system uses a wet chemical front end,followed by gold preconcentration and detection using atomicfluorescence. The system samples full strength stack gas and splits thesample into a first path that uses an alkaline-based stannous chloridesolution to convert all mercury forms into elemental mercury, and asecond path that uses a tris-buffer or potassium chloride (KCl) solutionto scrub out ionic mercury while passing elemental mercury. This system,however, requires the complex preparation of two different, low mercuryreagents on a continuing basis, and is subject to high maintenance whenused for extended periods of time. Use of liquid chemical agents mayalso produce toxic waste.

As a further example, conventional thermal conversion analyzers usethermal pyrolysis units to decompose the ionic mercury in gas samplesinto elemental form for subsequent analysis by AA detectors, forexample, to determine a measure of the total mercury in the samples.Some known analyzers of this type utilize a stainless steel thermalpyrolysis unit coupled to a gold adsorption cartridge; mercury isadsorbed onto the cartridge during sampling and is thermally desorbedduring an analysis phase. However, these analyzers typically suffer fromrecombination problems in the presence of hydrogen chloride (HCl) orchlorine (Cl₂). In particular, the very poor transport characteristicsof mercury chloride (HgCl₂) means that this component of sample gas willnot reach the gold cartridge in a timely manner, resulting in erroneousreadings and memory effects. Even where direct M analyzers are used,HgCl₂ may not be detected at all within the M cell since it does notabsorb efficiently at the primary mercury adsorption line.

Some other known thermal conversion analyzers utilize carbon-basedpyrolysis units. The problem with these pyrolysis units is that impuresubstances that prevent the reduction of the mercury or its release fromthe carbon, or which reoxidize already-reduced mercury, may accumulatein the carbon. In fact, conventional materials such as carbon, as wellas quartz chips, stainless steel, alumina, and molecular sieve materialsmay produce excessive recombination after a period of continuousrunning, even where the concentration of stack gas components may havebeen greatly reduced through prior dilution.

Some attempts have been made to utilize solid sorbents such as calciumcarbonate, sodalime, and calcium oxide to remove acid gases. However,these have not been applied commercially to a large extent, due to theirvery short lifetimes and their tendency to affect the accuracy ofmercury readings towards the end of their lifetimes. The characteristicsof solid sorbents may also change whenever the sample matrix changes.

The reliability of some other proposed remedies in preventing theformation of oxidized forms of mercury, such as the injection ofhydrogen gas into a stack matrix after thermal dissociation, may also bequestionable. The injection of hydrogen favors the creation of HCl,which is a powerful compound for causing recombination of elementalmercury into molecular species.

SUMMARY OF THE INVENTION

Embodiments of the invention relate generally to improved systems andmethods for detecting total mercury and/or speciating mercury. In atleast one embodiment of the invention, an improved conditioning moduleis provided, which may be used in a continuous emissions monitoringsystem (CEM) to analyze stack gas emissions, for example.

In one broad aspect, the invention is generally directed to the use ofsilicon carbide as pyrolyzer material in a thermal pyrolysis unit. Inanother broad aspect, the invention is directed to the use of siliconnitride, silicon boride, or boron nitride as pyrolyzer material in athermal pyrolysis unit. The inventors have realized that these materialsprovide the ability to reduce all forms of mercury to elemental form,and further, prevent recombination before the removal of acid gasspecies. These materials are unusually resilient, for thermal pyrolyzersoperating over a wide temperature range and with a wide variety of gasmatrices.

In another broad aspect, the invention is generally directed to animproved pyrolyzer design, in which a thermal pyrolysis unit comprises atailpiece that allows water (or other reagent) to be injected at aheated exit of the thermal pyrolysis unit. This design facilitatesprompt and efficient removal of offending gases before recombination canoccur.

In another broad aspect, the invention is generally directed to ascrubber unit that comprises a coalescing filter, which prevents waterfrom entering the gas phase sample path.

In another broad aspect, the invention is generally directed to ascrubber unit that comprises a hydrophobic filter membrane, whichprevents water from entering the gas phase sample path.

In accordance with a first aspect of the present invention, there isprovided a scrubber unit for use in a conditioning module for acontinuous emissions monitoring system, wherein the scrubber unitcomprises a coalescing filter element, and wherein in operation,pyrolyzed gas is passed through the coalescing filter element after thecoalescing filter element is saturated with a scrubbing liquid.

A second aspect of the present invention provides a scrubber unit foruse in a conditioning module for a continuous emissions monitoringsystem, wherein the scrubber unit comprises a hydrophobic filterelement, wherein the scrubber unit is adapted to receivemercury-containing gas that has been combined with a scrubbing liquidbut has not passed through a thermal pyrolyzer, separate the scrubbingliquid from the mercury-containing gas, and pass only themercury-containing gas through the hydrophobic filter element.

A further aspect of the present invention provides an apparatus forconditioning module for emissions testing, the apparatus comprising:

-   -   (a) an entry tube for receiving a stream of a liquid and gas        mixture;    -   (b) a distributor fitting connected with the entry tube, the        distributor fitting including at least one nozzle for ejecting        the liquid and gas mixture;    -   (c) at least one side positioned around said at least one        nozzle, whereby flow from said at least one nozzle maintains the        said at least one side wetted; and    -   (d) a hydrophobic filter membrane positioned above said at least        one side, the hydrophobic filter membrane allowing substantially        only gas in the liquid gas mixture passage to an exit.

BRIEF DESCRIPTION OF THE DRAWINGS

For a better understanding of various embodiments of the invention,reference will now be made, by way of example, to the accompanyingdrawings in which:

FIG. 1 is a schematic diagram illustrating components of an exampleimplementation of a continuous emissions monitoring system (CEM);

FIG. 2 is a schematic diagram of a conditioning module in an embodimentof the invention;

FIG. 3 is a schematic diagram of a tailpiece of a thermal pyrolysis unitfor a conditioning module in an embodiment of the invention;

FIG. 4 is a schematic diagram of a scrubber unit for a conditioningmodule in an embodiment of the invention;

FIG. 5 is a schematic diagram of another scrubber unit for aconditioning module in an embodiment of the invention; and

FIG. 6 is a flowchart illustrating steps of a method for measuringmercury in gaseous emissions in an embodiment of the invention.

DETAILED DESCRIPTION OF EMBODIMENTS OF THE INVENTION

At least some embodiments of the invention relate generally to a systemfor monitoring mercury in gaseous emissions, comprising: a samplingprobe for sampling the emissions; a conditioning module coupled to thesampling probe, which may be adapted to speciate mercury in theemissions, the conditioning module adapted for coupling to a mercuryanalyzer; a calibration module coupled to the sampling probe; and acontroller coupled to the conditioning module and the calibrationmodule. The conditioning module comprises a thermal converter and, insome embodiments, one or more scrubbing units. The thermal convertercomprises one or more pyrolyzer units, wherein at least one of thepyrolyzer units comprises material composed of silicon carbide, siliconnitride, silicon boride, boron nitride, and/or other similar covalentlybound material. At least one of the scrubbing units may comprise acoalescing filter used as an interference scrubber and gas/liquidseparator. At least one of the scrubbing units may comprise ahydrophobic filter membrane. These and other features of variousembodiments of the invention will now be described in greater detailwith reference to the Figures.

Referring to FIG. 1, a schematic diagram illustrating components of anexample implementation of a continuous emissions monitoring system (CEM)is shown generally as 10. CEM 10 is used to monitor stack gases, and atypical industrial stack is shown schematically at 20. Stack 20 mayproduce gaseous emissions generated from coal-fired power plants, forexample. It will be understood by persons skilled in the art that insome implementations, CEM 10 may be used in the analysis of emissionsfrom other industrial sources (e.g. waste incinerators or industrialprocess gases) and in applications such as speciation studies, benchscale testing, mercury removal process monitoring, and other analyses.

In this example implementation of CEM 10, a sample of stack gas is drawnoff from stack 20 by a heated probe element 30 coupled to a samplingprobe 32 mounted to stack 20. Sampling probe 32 is used to retrieve andpreprocess the sample before it is sent to a conditioning module 34 forsubsequent processing. In one example implementation, sampling probe 32is a conventional high flow rate inertial probe used to minimize mercurymeasurement artifacts due to filtering. The sample retrieved by probeelement 30 is passed through a coated inertial filter 36 of samplingprobe 32, which is then passed through a flow sensor 38 by a pump 40back out to stack 20 via probe element 42. During this process, asubsample is retrieved through inertial filter 36 to be diluted using adiluter 44, which is then transferred at a high velocity through aheated sample line 46 to conditioning module 34 at 48. Dilution at thesampling point enables CEM 10 to respond rapidly to changes in mercuryconcentrations in gas samples, since it reduces the concentration ofmercury and stack gas components within the transfer line andconditioning module components.

The transfer temperature is chosen to allow rapid quantitative transportof the mercury species through heated sample line 46 without materiallyaffecting the speciation. Temperatures of about 100 to about 180° C. cantypically be used for heated sample line 46. Heated sample line 46 mayalso be used to send zero or dilution air [not shown] provided byconditioning module 34 to sampling probe 32. Heated sample line 46 mayalso be used to send data signals and the main flow eductor supply air(i.e. motive air supply) [not shown] to sampling probe 32. Heated sampleline 46 may also be used to send spike and calibration gases providedthrough outlets 52 of a calibration module 54 to sampling probe 32 forcalibration purposes. Calibration module 54 provides a source ofconstant, known concentration elemental mercury to CEM 10 forcalibration and sample spiking purposes.

CEM 10 also comprises a mercury analyzer 56 to analyze output fromconditioning module 34 at 58. In one example implementation, the mercuryanalyzer 56 is a conventional gold pre-concentration/atomic fluorescenceanalyzer of the type described in U.S. Pat. No. 5,597,535, the contentsof which are herein incorporated by reference. Other U.S. patents issuedto the present inventors and related generally to mercury detection areU.S. Pat. Nos. 5,660,795 and 6,475,802, the contents of which are hereinincorporated by reference.

A computerized control system [not shown] controls each module and thesampling probe within CEM 10. All temperatures, flows and pressures aredisplayed by an application program, and may be set by authorized users.The control system may feature remote operation and problem diagnosis,either via a modem and telephone line or through the Internet.

Embodiments of the invention relate generally to an improvedconditioning module that may be used in a CEM (e.g. conditioning module34 of CEM 10 of FIG. 1). It will be understood by persons skilled in theart that CEM 10 of FIG. 1 is illustrative of only one exampleimplementation. A conditioning module constructed in accordance with anembodiment of the invention may be used in CEMs of differentconfigurations and constructions in variant implementations. Inparticular, a conditioning module constructed in accordance with anembodiment of the invention may be used with other probes (e.g., mostconventional probes capable of quantitatively sampling mercury specieswhile excluding particulates, inertial probes, extraction probes), othercalibration modules, other sample line configurations and constructions,other mercury analyzers (e.g., atomic fluorescence analyzers, atomicabsorption analyzers), and other control systems, for example, invariant implementations of a CEM. By way of further example, the variousmodules could also be combined into one physical unit, eliminating theheated line, in variant implementations.

A conditioning module constructed in accordance with an embodiment ofthe invention will now be described in greater detail with reference toFIG. 2.

Referring now to FIG. 2, a schematic diagram of a conditioning module inan embodiment of the invention is shown generally as 34. Conditioningmodule 34 may be used in a CEM, such as the implementation of CEM 10shown in FIG. 1, for example.

Conditioning module 34 (which may also be referred to more generally asa conditioning system) is adapted to provide either or both totalmercury or elemental mercury values. Conditioning module 34 speciatesmercury in a gas sample provided as input at 48 into elemental and ionic(water-soluble) forms without the use of chemical reagents or solidsorbents. This is performed through thermal pyrolysis and, optionally,pre-dilution of the gas sample, in order to eliminate recombination ofpyrolyzed mercury into molecular form.

A gas sample is received by conditioning module 34 as input at 48 (e.g.as obtained from sampling probe 32 of FIG. 1), and enters a heatedenclosure 60 in conditioning module 34. The gas sample is split into twostreams, each corresponding to a different analytical path.

First Analytical Path: Total Mercury Measurement (Hg^(T))

In the first analytical path, a connector 62 directs a sample streamthrough a thermal pyrolysis unit 64 (“thermal pyrolyzer”), which isheated within a pyrolyzer oven that defines a heated pyrolysis zone 66.Thermal pyrolyzer 64 is exposed directly to the gas sample, and is usedto convert all mercury forms present in the sample into elemental form.

Exhaustive tests performed by the inventors revealed that conventionalfill materials for thermal pyrolyzers, such as quartz chips, stainlesssteel, carbon, alumina, and molecular sieve materials, all producedexcessive recombination after a period of continuous running, even whensamples of stack gas were greatly reduced in concentration through priordilution. In contrast, the inventors have realized that inert covalentlybonded materials like silicon carbide (e.g. SiC), silicon nitride (e.g.Si₃N₄), silicon boride (e.g. SiB₆), and boron nitride (e.g. BN) providethe unique ability to reduce all forms of mercury to elemental form, andfurther, to prevent recombination before removal of acid gas species.These materials are resilient as a material for thermal pyrolyzers,operating over a wide temperature range and processing samples of a widevariety of stack gas compositions.

In accordance with one embodiment of the invention, thermal pyrolyzer 64contains one or more of the above-mentioned materials as a fill material67. The material may be in coarse granular form, for example, to allowpassage of the sample gas therethrough. In a variant embodiment, a long,narrow tube of at least one of the above-mentioned materials (e.g. asilicon carbide denuder) is employed in thermal pyrolyzer 64.

In one embodiment, the material for the thermal pyrolyzer used isstandard industrial grade silicon carbide, which is typically employedfor a different purpose in other industrial applications, namely as anabrasive. However, this material may provide some practical advantageswhen used with thermal pyrolyzers in the context of this embodiment ofthe invention, in that the material is relatively inexpensive andreadily available. A typical analysis of silicon carbide used in oneexample implementation is as follows:

-   -   SiC Typical Chemical Analysis    -   Silicon Carbide: 98.4%    -   Silicon: (Free) 0.63%    -   Silicon Dioxide: (Free) 0.57%    -   Carbon: (Free) 0.25%    -   Iron: 0.16%    -   Aluminum: 0.23%

Calcium Oxide: 0.05%

Magnesia: 0.05%

In variant embodiments of the invention, other covalently bondedmaterials similar to the materials identified above may be employed inthermal pyrolyzer 64.

The gas sample in this analytical path is pulled through thermalpyrolyzer 64 to convert the sample into pyrolyzed gas, in which allmercury in the sample is reduced to elemental form. Since thermalpyrolyzer 64 is exposed directly to the gas sample (e.g. derived fromthe sample originally obtained from stack 20 of FIG. 1), the mercury(now converted into elemental form) in the pyrolyzed gas can be detectedby a mercury analyzer (e.g. mercury analyzer 56 of FIG. 1) to measurethe concentration of total mercury in the gas sample (i.e. accountingfor both mercury that was originally in elemental form and mercury thatwas originally in ionic form).

In one embodiment of the invention, thermal pyrolyzer 64 comprises atailpiece 68. Tailpiece 68 is described in greater detail with referenceto FIG. 3.

Referring to FIG. 3, a schematic diagram of a tailpiece of a thermalpyrolysis unit for a conditioning module in an embodiment of theinvention is shown generally as 68.

The design of tailpiece 68 in this embodiment of the invention addressesa number of potential problems that may arise in the analysis of a gassample. Any elemental mercury in the heated pyrolysis zone 66 will havea natural tendency to combine as it cools down after exiting the heatedzone. The presence of free halogens (e.g. Cl₂) and oxidizing gases (e.g.HCl) can make recombination even more likely. Any ionic mercurycompounds so produced would coat the surfaces of conditioning elements,which can result in slow response and carryover. Furthermore, whereionic mercury present at this point (whether originally present or newlycreated by recombination) is subsequently scrubbed from the samplestream, this may result in an anomalously low total mercury measurement.Moreover, trace compounds present in virtually all coal-fired powerplant gas matrices will typically leave residual deposits at the exit ofa thermal pyrolyzer. For example, ammonia salts may be created, whereammonia has been injected into the matrix as part of pollution abatementtechniques. These volatile, water-soluble salts sublimate out when thesample gas cools after exiting the thermal pyrolyzer. These deposits canretain mercury and release it later, which can generate anomalousmeasurements. In severe cases, the deposits can build up and restrictthe flow of gases through the conditioning module.

In accordance with this embodiment of the invention, the tailpiece 68for a thermal pyrolyzer 64 facilitates the prompt and efficient removalof offending gases before recombination can occur, and the flushing ofdeposits before they can build up to create analytical problems. Thedesign of tailpiece 68 is such that a scrubbing liquid (e.g. water, orother reagant) is introduced directly into the heated tail of thermalpyrolyzer 64. The scrubbing liquid enters at 70 through one connector ofan arrangement of connectors and fittings 72 (e.g. made of Teflon), intoan outer jacket 74 defined by an inner tube 76 and the inner surface ofconcentric outer tube 78 of tailpiece 68. The scrubbing liquid iscarried upwards within outer jacket 74 directly into heated pyrolysiszone 66, so that the acid gas and deposit removal process occursdirectly within heated pyrolysis zone 66.

In this embodiment of the invention, inner tube 76 is made of nickel orother inert material so as not to cause mercury losses. Outer tube 78 oftailpiece 68 is made of quartz glass, which has good thermal insulatingproperties. Accordingly, at the point where scrubbing liquid isintroduced, tailpiece 68 and the sample gas is still sufficiently hot sothat recombination cannot occur. This high gas temperature is possibledue to the insulating characteristics of outer tube 78 of tailpiece 68.

This construction for tailpiece 68 also eliminates any “dry” areas wheremercury could recombine and where resultant HgCl₂ could deposit, whichcan result in slow response times. The efficient flushing actionproduced by the scrubbing liquid ensures that any soluble acid gases inthe sample stream are dissolved into the liquid, and are removed fromthe gaseous sample stream while the sample is emerging from thermalpyrolyzer 64 and is still hot, before recombination can occur. Thisflushing action also efficiently removes all water-soluble salts thatmight otherwise build up in tailpiece 68.

The sample gas and scrubbing liquid are carried out via inner tube 76,and out of tailpiece 68 at 80. The sample gas and scrubbing liquid canbe separated in subsequent processing. The alternating bubbles of liquidand gas in the sample stream within tailpiece 68 of thermal pyrolyzer 64provide sufficient surface area for acid gases to be dissolved into theliquid. As well, the action of the liquid ensures that all of thesurfaces downstream of thermal pyrolyzer 64 are continuously washed,removing deposits that would otherwise build up over time.

Referring again to FIG. 2, in one embodiment of the invention, thepyrolyzed gas produced by thermal pyrolyzer 64 is subsequently scrubbedusing a scrubber unit 82 before being passed to a mercury analyzer.Scrubber unit 82 removes water-soluble acid gases, such as hydrogenchloride, sulfur dioxide, sulfur trioxide, and oxides of nitrogen fromthe pyrolyzed gas, yielding a sample that may be more safely analyzed bythe mercury analyzer. Scrubber unit 82 also removes moisture in thepyrolyzed gas to prevent condensation in downstream lines leading to themercury analyzer. Scrubber unit 82 in this embodiment of the inventionis described in greater detail with reference to FIG. 4.

Referring to FIG. 4, a schematic diagram of a scrubber unit for aconditioning module in an embodiment of the invention is shown generallyas 82. In this embodiment of the invention, scrubber unit 82 forms apart of the first analytical path (total mercury measurement) inconditioning module 34 of FIG. 2, and is connected directly aftertailpiece 68 of thermal pyrolyzer 64. Scrubber unit 82 is used toseparate the scrubbing liquid from the gaseous sample. Pyrolyzed gas isreceived as input to scrubber unit 82 at 80, and is forced to passthrough a coalescing filter element.

In one implementation, scrubber unit 82 is a conventional commerciallyavailable disposable filter unit (DFU) 84 containing a coalescing filterelement 86 extending from a solid body portion 88, and modified so thatthe filter element 86 is reduced in size and mounted within a lower,cooled region of scrubber unit 82. The entire scrubber unit 82 ischilled (e.g. to approximately 3° C. by a chiller block 90 in oneexample implementation, as shown in FIG. 2) so that the dew point of theresulting gas at 92 is lower than the ambient temperature of the mercuryanalyzer.

The liquid/gas mixture of the pyrolyzed gas is introduced through acenter top fitting at 80 and runs into the filter element 86, whichbecomes saturated with the scrubbing liquid. Filter element 86 providesa medium for capturing a wide range of water-soluble species into theaqueous phase. Filter element 86 is also effective at scrubbing outsulphur trioxide aerosols that may be present, for example, whichtypically passes through conventional impingers without being trapped.The pyrolyzed gas passes through filter element 86, travels upwardsthrough an outer annular area 94, and emerges through a side portfitting at 92, which may then be passed to a mercury analyzer foranalysis. This unit provides intimate contact between the gas stream andthe liquid scrubbing medium, allowing for efficient removal of residualacid gases.

The gas is chilled as it passes up the outer annular area 94, andmoisture condenses on the inner and outer walls of the DFU 84. Bothliquid previously added (e.g. as discussed with reference to FIG. 3) andthe condensate formed during cooling will drain out of the DFU 84through the bottom fitting at drain outlet 96 to drain 98 (FIG. 2), toensure rapid removal of the liquid, and to prevent standing liquid fromcollecting in scrubber unit 82. If the chillers are operated at negativepressure, an active pumping system is required to remove the liquid inscrubber unit 82. If operated under positive pressure, only a flowrestrictor is required to produce the draining action. The drainingaction permits scrubber unit 82 to have low internal dead volume and noreservoir of liquid, enabling it to respond rapidly to changes in sampleconcentration. If liquid were allowed to remain in the filter unit forextended periods, it would become acidic. This acidic liquid wouldfoster oxidation of mercury. This oxidized mercury would then be removedalong with the liquid, resulting in analytical losses within the system.

Although simple, inexpensive, and disposable, a DFU will typically lastfor several months of continuous operation in a typical coal-fired powerplant installation.

Referring again to FIG. 2, pyrolyzed gas is scrubbed as it passesthrough the scrubber unit 82, and emerges at 92 as scrubbed gas, whichmay then be passed to a mercury analyzer (e.g. mercury analyzer 56 ofFIG. 1) for analysis. It is desirable to maintain the flow rate throughconditioning module 34 at a constant level. Flow through conditioningmodule 34 is provided by either a pump located within the mercuryanalyzer 56 or by a bypass pump and flow regulator 100, 102 to a vent104, depending on the setting of valves 106, 108. These elements will bedescribed in further detail later in this description followingdiscussion of the second analytical path, provided below.

Second Analytical Path: Elemental Mercury Measurement (Hg⁰)

In the second analytical path, connectors 62, 110 direct a sample streamto a separate scrubber unit 112 in an embodiment of the invention. Anyexcess sample gas not required for analysis may be vented through vent148. In this embodiment, scrubber unit 112 samples directly from thesample stream and is used to remove water-soluble (i.e. ionic) forms ofmercury from the sample prior to subsequent processing. Scrubber unit112 is also used to remove harmful potential interferents from thesample in producing a scrubbed gas at 114. As a result, while ionicforms of mercury will be scrubbed out, the elemental mercury originallypresent in the sample will be quantitatively passed through scrubberunit 112 in producing scrubbed gas at 114. As a result, the mercurydetected in scrubbed gas 114 can be used to obtain a measure of theconcentration of elemental mercury originally present in the sample.

In one embodiment of the invention, scrubber unit 112 is of a differentdesign than scrubber unit 82, to account for the fact that the samplestream to which scrubber unit 112 is exposed may contain significantconcentrations of HgCl₂. Unlike scrubber unit 82, which is exposed onlyto elemental mercury in the first analytical path, scrubber unit 112 inthe second analytical path is exposed to the full stack gas matrix,which can include both elemental mercury and HgCl₂. As a result, thesurface area inside of a scrubber unit 112 must be minimized in order toreduce deposition of HgCl₂. Any ionic mercury compounds that formdeposits would coat the surfaces of conditioning elements, which canresult in slow response time and carryover.

Furthermore, as much of all exposed surfaces within a scrubber unit 112should be wetted to remove any deposited mercury chloride. In theembodiment of the invention shown in FIG. 2, water is used as ascrubbing liquid, and supplied to the sample stream from a reservoir 116by a peristaltic pump motor 118 through connector 110 (alternatively, apressurized water supply may be used). Reservoir 116 also supplies waterfor the first analytical path via tailpiece 68 described earlier withreference to FIG. 3.

While a range of chemical reagents may be used in scrubber units 82 and112, the ability of a conditioning module design that works with plainwater can provide certain advantages over conventional approaches. Forexample, plain water is readily available, inexpensive, and does notrequire special preparation or disposal.

A scrubber unit 112 designed in accordance with an embodiment of theinvention will now be described in greater detail with reference to FIG.5.

Referring to FIG. 5, a schematic diagram of a scrubber unit for aconditioning module in an embodiment of the invention is shown generallyas 112. In this embodiment of the invention, scrubber unit 112 forms apart of the second analytical path (elemental mercury measurement) inconditioning module 34 of FIG. 2. Scrubber unit 112 is used to removemercury chloride and other acid gas components while allowing elementalmercury in the sample stream to pass through unimpeded. Accordingly,scrubber unit 112 facilitates more accurate determination of theelemental mercury originally present in the initial sample. Scrubberunit 112 also acts as a liquid/gas separator to ensure that only drysample gas is passed on, for output to a mercury analyzer, for example.

In this embodiment, scrubber unit 112 is made out of Teflon-coatedmetal, although other inert materials may also be used. Scrubbing liquidis introduced into the sample stream ahead of scrubber unit 112 via aconventional T-fitting of connector 110 (FIG. 2). The mixed liquid/gassample enters through a bottom fitting at 120. A T-shaped distributorfitting 122 at the top of an entry tube 124 ejects liquid horizontallyso that it coats the sides 126 of scrubber unit 112. Althoughdistributor fitting 122 is shown with two nozzles 128 in FIG. 5,distributor fitting 122 may have a different number of nozzles 128 invariant implementations.

Sample gas proceeds upwards and passes through a hydrophobic (e.g.Teflon) filter membrane 130 and exits at 114. Only gas can pass throughthis filter membrane 130. The liquid ejected through distributor fitting122 is ejected sideways so that liquid droplets do not come into contactwith filter element 130. This prevents plugging and fouling of thefilter element that might otherwise occur as impurities in the liquidstream evaporate after being deposited on filter membrane 130.

The liquid ejected from distributor fitting 122 runs downward and coatsthe sides 126 of scrubber unit 112. This results in an efficient washingof the inner surfaces of scrubber unit 112. This washing action isperformed to remove all traces of gaseous HgCl₂ and other soluble salts.The liquid is removed via a drain outlet at 132 to drain 98 (FIG. 2).The low internal volume and minimal exposed surface area ensure quickremoval of all liquids and rapid exchange of gases. This minimizesbuildup of residual mercury chloride and its subsequent release into theanalytical gas stream.

For convenience, the entire top of scrubber unit 112 may be removable toallow easy changing of filter membrane 130, in a variant embodiment ofthe invention. The top can be pushed on and held in place by dualO-rings 134.

It will be understood by persons skilled in the art that additionalpyrolyzer units or scrubber units may optionally be employed in eitheror both of the first and second analytical paths for added safety invariant implementations, and such variant implementations are intendedto be within the scope of the invention.

Sample Switching Unit

Referring again to FIG. 2, sample gas processed by conditioning module34 is split into two separate analytical paths, with the gas beingpassed through each of the two paths continuously. This allows both atotal mercury measurement and an elemental mercury measurement to beobtained. In one example implementation, separate mercury analyzers maybe employed so that both of these measurements can be madesimultaneously. In this case, a first mercury analyzer is used toanalyze gas emerging as output from the first path, while a secondmercury analyzer is used to analyze gas emerging as output from thesecond path.

In another example implementation, as shown in FIG. 2, a switching unitis implemented using two four-way inert solenoid valves 106, 108. Valves106, 108 are actuated to direct gas from one path to a mercury analyzer(e.g. via output 152 to a mercury analyzer 56 of FIG. 1). If desired,the switching unit can be employed to enable a single mercury analyzerto alternately sample gases emerging as output from the first and secondpaths respectively.

In another example implementation, multiple conditioning modules may becascaded to allow multiple stacks to be monitored using a single mercuryanalyzer. In this case, input 150 can accept the output 152 from aprevious cascaded conditioning module 34 and present it to the mercuryanalyzer 56.

If the conditioning module 34 is “not ready” for any reason, zero air(e.g. via input 150 when conditioning module 34 is not coupled toanother conditioning module) can be directed to the mercury analyzer toprevent contamination of, or damage to the analyzer. Valves 106, 108 arealso coupled to a vent at 104 via bypass pump and flow regulator 100,102. This permits all idle paths within the switching unit to becontinually flushed. If the analyzer is not sampling a particularsampling path, bypass pump and flow regulator 100, 102 ensure thatsample gas continues to flow through the paths of conditioning module 34at approximately the same flow rate to ensure that components along thepath remain conditioned and in equilibrium.

As indicated earlier, gas emerging as output from the first path may beused to obtain a total mercury measure (Hg^(T)), while gas emerging asoutput from the second path may be used to obtain an elemental mercurymeasure (Hg⁰) by the mercury analyzer. These two measures can also beused to determine a third measure: an ionic mercury measure calculatedas the difference between the total and elemental mercury measures.

Additional Considerations

While not explicitly shown in FIG. 2, it will be understood by personsskilled in the art that conditioning module 34 will generally compriseother elements, such as heating elements, temperature sensors, pressuresensors, back-up protection sensors, control switches, and fan elements,for example, for use in the operation and control of conditioning module34. Probe temperatures, flow rates and pressures within conditioningmodule 34, for example, can be monitored and telemetered to the systemcontroller via a data communications link [not shown].

It will also be understood by persons skilled in the art, that the abovedescription of conditioning module 34 relates to a number of exampleimplementations, and that other types and constructions of conditioningmodule 34 may be employed in variant implementations of CEM 10 withoutdeparting from the scope of the invention.

For example, although the example implementation of FIG. 2 employs aconditioning module 34 that speciates mercury, a subset implementationused only for total mercury measurement may be constructed. One suchimplementation may comprise a single pyrolyzer unit, and a singlechiller component with no switching valves, for example.

By way of further examples, the use of such covalently bonded materialsas silicon carbide, silicon nitride, silicon boride, and boron nitridecan be employed in thermal pyrolyzers within conditioning modules andsystems where speciation is not attempted. The coalescing filter andhydrophobic filter element described herein can be used to remove acidgases from sample streams, pyrolyzed or not pyrolyzed, in conditioningmodules and systems where speciation is not attempted. Such variants areintended to be within the scope of the invention.

Now referring to FIG. 6, a flowchart illustrating steps of a method formeasuring mercury in gaseous emissions in an embodiment of the inventionis shown generally as 200. The details of certain steps of method 200are provided in summary form; additional details with respect to varioussteps of method 200 can be found in the above description.

At step 210, in preparation for the conditioning process, thermalpyrolyzers of a conditioning module (e.g. thermal pyrolyzer 64 ofconditioning module 34 in FIG. 2) are heated before gases to be analyzedare passed therethrough. The scrubbers are cooled to their requiredtemperature. Thereafter, the conditioning components are continuallymaintained at their optimum temperatures.

In this embodiment, the conditioning process is a continuous process,and the following steps are performed continuously.

At step 212, a sample of mercury-containing stack gases is retrievedfrom a sampling probe (e.g. sampling probe 32 of FIG. 1). In one exampleimplementation, the sample is diluted at the sampling probe.

The sample gas is the split into two streams, and fed continuously andsimultaneously to two different analytical paths. Unneeded gas isvented.

First Analytical Path

Within the first analytical path, at step 214, the sample gas is passedthrough a thermal pyrolyzer to reduce the mercury therein to elementalform, producing a pyrolyzed gas. In accordance with an embodiment of theinvention, the thermal pyrolyzer contains an inert covalently bondedmaterial such as silicon carbide, silicon nitride, silicon boride,and/or boron nitride as fill material. In accordance with an embodimentof the invention, the thermal pyrolyzer comprises a tailpiece describedwith reference to FIG. 3. At step 216, the pyrolyzed gas is then passedthrough a scrubber unit (e.g. scrubber unit 82 of FIG. 2). In accordancewith an embodiment of the invention, the scrubber unit contains acoalescing filter element as described with reference to FIG. 4. Outputfrom the scrubber unit can then be passed to a mercury analyzer (e.g.mercury analyzer 56 of FIG.

1) at step 218, to determine a total mercury measure from the elementalmercury in the pyrolyzed gas.

Second Analytical Path

Within the second analytical path, at step 220, the sample gas is passedthrough a scrubber unit (e.g. scrubber unit 112 of FIG. 2) to removesubstantially all water-soluble forms of mercury therefrom andquantitatively pass elemental mercury. In accordance with an embodimentof the invention, this scrubber unit contains a hydrophobic filtermembrane as described with reference to FIG. 5. Scrubbed gas produced bythe scrubber unit can then be passed to a mercury analyzer at step 222,to determine an elemental mercury measure from the scrubbed gas.

Path Selection

In one implementation where the use of a single mercury analyzer isdesired, valves and switches may be employed to allow selection of oneof the two paths for analysis at a particular point in time, asindicated at step 224. In another implementation, the gas from bothanalytical paths can be sent to separate mercury analyzers for analysis[step 224 is not performed]. The mercury analyzer(s) used in determiningthe total and elemental mercury measures can also be used to determinean ionic mercury measure, by calculating the difference between thetotal and elemental mercury measures.

As indicated earlier with respect to conditioning module 34, variationsmay be made to the method 200 without departing from the scope of theinvention. For example, in a variant embodiment, a method may comprisesteps to process a sample gas using only one analytical path, todetermine a total mercury measurement.

While embodiments of the invention have been described herein withreference to a system in which a diluted sample is processed, in variantimplementations, embodiments of the invention may also be employed insystems in which the samples to be processed are not diluted.

The invention has been described with reference to particularimplementations and embodiments. However, it will be understood bypersons skilled in the art that a number of other variations andmodifications are possible without departing from the scope of theinvention.

1. A scrubber unit for use in a conditioning module for a continuousemissions monitoring system, wherein the scrubber unit is adapted toreceive a flow stream comprising a mercury-containing gas that has beencombined with a scrubbing liquid but has not passed through a thermalpyrolyzer, separate the scrubbing liquid from the mercury-containinggas, and pass only the mercury-containing gas through the hydrophobicfilter element, wherein the scrubber unit comprises: interior sides; adistributor fitting that distributes the flow steam onto the sides, toenable separation of the scrubbing liquid from the mercury-containing;an inlet fitting for the flow stream connected to the distributorfitting; a hydrophobic filter element situated above and upstream fromthe distributor fitting; an outlet for gas downstream from thehydrophobic filter element; and a drain outlet for liquid below thedistributor filling.
 2. The scrubber unit of claim 1, wherein thedistributor fitting comprises at least one nozzle, each providing anoutput such that gas in the output moves towards the hydrophobic elementand liquid in the output moves away from the hydrophobic element towardsthe outlet drain.
 3. The scrubber unit of claim 2 in combination with afirst scrubber unit comprising a filter unit including a coalescingfilter element at a lower end thereof, an inlet for pyrolyzed gas, anoutlet for liquid below the filter element, a port for discharging gasabove the filter element, and a chiller surrounding at least a lowerportion of the filter unit, wherein in operation pyrolyzed gas is passedthrough the coalescing filter element after the coalescing filterelement is saturated with a scrubbing liquid, wherein the scrubber unitof claim 2 provides a second scrubber unit, and wherein a common inletfor a gas sample is connected through first and second connectors, thefirst connector being connected to the first scrubber unit and thesecond connector being connected to the second scrubber unit.
 4. Thescrubber units as claimed in claim 3, wherein the first and secondscrubber units are mounted in a common chiller.
 5. An apparatus for aconditioning module for emissions testing, the apparatus comprising: (a)an entry tube for receiving a stream of a liquid and gas mixture; (b) adistributor fitting connected with the entry tube, the distributorfitting including at least one nozzle for ejecting the liquid and gasmixture; (c) at least one side positioned around said at least onenozzle, whereby flow from said at least one nozzle maintains the said atleast one side wetted; (d) a hydrophobic filter membrane positionedabove said at least one side, the hydrophobic filter membrane allowingsubstantially only gas in the liquid gas mixture to pass to an exit; (e)an outlet for gas downstream from the hydrophobic filter membrane; and(f) a drain outlet for liquid below the distributor fitting.
 6. Theapparatus of claim 5, wherein the hydrophobic filter membranesubstantially separates the gas from a liquid in the liquid and gasmixture.
 7. The apparatus of claim 6, wherein said at least one side isprovided by a body with a generally circular cross-section, defining aninterior of the body.
 8. The apparatus of claim 7, wherein the interiorof the body comprises an open top end and bottom end, and an outlet forliquid adjacent the bottom end with the bottom end being otherwiseclosed.
 9. The apparatus of claim 8, wherein the entry tube for theliquid and gas mixture extends up through the bottom end into theinterior of the body.
 10. The apparatus of claim 9, wherein said atleast one side of the body is angled outwardly toward the top end suchthat an upper portion of the body is frustro-conical.
 11. The apparatusof claim 10, wherein the nozzles eject the liquid and gas mixture ontoinner surfaces of said at least one side of the body in the upperportion.
 12. The apparatus of claim 11, wherein the liquid and gasmixture is ejected by the nozzles in a generally horizontal direction.13. The apparatus of claim 5, wherein the distributor fitting, said atleast one nozzle and said at least one side are formed of inertmaterial.
 14. The apparatus of claim 13, wherein the inert materialcomprises polytetrafluoroethylene coated metal.
 15. The apparatus ofclaim 14, wherein the hydrophobic filter membrane is formed ofpolytetrafluoroethylene.
 16. The apparatus of claim 7, wherein the bodyis formed of metal coated with an inert coating.
 17. The apparatus ofclaim 8, wherein the hydrophobic filter element is formed of one ofpolytetrafluoroethylene and another inert, hydrophobic material.